1. General Information ............................3 1.1 Contents of This Manual ..........................3 1.2 Machine Safety ............................3 1.3 Indemnification ............................4 1.4 Hardware and Software Changes ........................ 4 1.5 Machine Serial Plate ............................ 5 1.6 Customer Support ............................5 2. Technical Information ............................6 2.1 Description of the Bar Feeder ........................
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6.4 Synchronization System ..........................35 6.5 Rotating Tip ..............................36 6.6 Pre-Feed Pusher and Pusher ........................37 6.7 Guide Channel System ..........................38 6.8 Shuttle – Extraction / Introduction Cylinder ....................42 6.9 Channel Lock System ..........................43 6.10 Material Standards and Requirements ....................44 6.11 Procedure to Check Bar Straightness ......................
1. General Information Please read and understand the manual before operating the bar feeder. Failure to do so could result in hazardous conditions that could result in severe injury or even death, and could cause material damage to the bar feeder. 1.1 Contents of This Manual The bar feeder manufacturer has provided this manual as an integral part of the bar feeder.
1.3 Indemnification The operator agrees to indemnify and hold harmless Edge Technologies from all claims or liabilities from accidents involving the bar feeder caused by failure of operators, employees, or agents to follow instructions, warnings, or recommendations furnished by Edge Technologies, or by failure of the user to comply with federal, state, and local laws applicable to such equipment, including the occupational Safety and Health Act of 1970.
1.5 Machine Serial Plate Important Information: When inquiring about parts or service, please have the machine model type and serial number available. Refer to the machine data plate pictured above for information. 1.6 Customer Support For the Parts department, contact us at (314) 810-3959, or via email at orderdesk@edgetechnologies.com.
2. Technical Information 2.1 Description of the Bar Feeder The Patriot is an automatic bar feeder controlled by a Programmable Logic Controller (PLC) and designed for both fixed headstock lathes and Swiss-type (sliding headstock) lathes. It can handle a wide variety of material profiles, such as round, hex, and square stocks, and can be adapted to feed materials with a more unique shape.
2.2 Following Features (1) Guide channel set. Several sizes are available, and each handles a specific stock range. Refer to the chart on the following page. (A spindle liner is required if the channel set is not the lathe’s max capacity.) (1) O.D.
2.3 Installation Area The floor on which the bar feeder is placed must be designed to bear the loads. Non-observance can lead to material damage. The Patriot must be bolted to a sound, level floor using anchor bolts. The area surrounding the machine must allow sufficient clearance for the operator to access both sides and the rear of the machine, as shown in the diagram below.
2.6 Guide Channel Specifications Use the channel set recommended for the bar stock diameter to avoid bar feeder or lathe damage. For a complete list of available guide channels, review the Parts section at the end of this manual, or visit www.edgetechnologies.com. [11]...
2.7 Compressed Air Supply, Including Oil When working with compressed air, proper PPE is required in accordance with federal, state, and local laws. Flying air particles can be a hazard for eyes and exposed parts of the body. Compressed air supply must be available for machine operation. The supply hose for compressed air supply must be larger than 8 mm.
3. Safety Safety switches should always be connected and in place during bar feeder operation. The Patriot is designed to be safe and reliable. Only trained personnel should operate the bar feeder. Personnel should be familiar with the operating instructions of the equipment before using it and should follow standard safety practices.
Failure to do so may result in injury or damage to the equipment. Normally, a bar feeder is ordered from Edge Technologies to be used with a specific lathe model. The wiring interface is set in accordance with the most current information received by Edge Technologies.
The interface cable is pre-wired for the lathe application when shipped from Edge Technologies. Verify the connection to the lathe before applying voltage to the system. The lathe must support a bar feeder interface for the two machines to be connected.
4. Transportation and Handling Without packaging, the Patriot weighs approximately 2,800 lbs. Only trained operators are to use lifting equipment. Improper handling can result in an operator being crushed. Verify that the equipment to be used for moving the machine is rated to safely lift the weight of the bar feeder plus the packaging material.
4.2 Transportation and Hoisting Hoisting the bar feeder Attach the hooks of suitable web slings to eyebolts attached to the core beam inside to bar feeder. Hoisting with bar feeder on pallet Position suitable lifting straps under the pallet near the stands.
5. Installation 5.1 Lathe Preparation Prior to installing the bar feeder, the lathe installation must be completed and ready to produce parts. If no lathe spindle workholding is installed and if no compressed air is supplied, the bar feeder cannot be installed. Only qualified electricians or servicemen should perform any electrical troubleshooting or maintenance to this equipment.
5.2 General Installation Guide The following steps are to be performed by a trained technician. Step 1: Inspect the bar feeder for damage. Carry out a detailed inspection of the bar feeder to ensure no components have been physically damaged. Step 2: Make sure the location has all required items they will need.
5.3 Bar Feeder Installation Process Inspect the bar feeder for any shipping or handling damage, and report as necessary. Verify the lathe installation condition. A. Lathe is level for operation. B. Lathe will power up. C. Lathe has a collet or chuck package. D.
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Drill and anchor bar feeder to floor. A. Verify floor is not heated. B. Drill holes complete through floor using an entire 12-inch drill stroke. C. Drive anchors completely into floor with associated fender and washers installed. D. Tighten anchors fully. Verify alignment, adjust as necessary.
5.4 Hand Crank Do not apply power to the bar feeder with the hand crank inserted into the servo gearbox. Otherwise, personal injury may result. A hand crank has been included that may be used to manually operate the pusher carriage when performing a channel changeover.
5.6 Axial Shift Instructions – Guide Bushing Mode to Non-Guide Bushing Mode Between the cabinets and the upper magazine is a mechanism called the axial track. The axial track contains 2 guide rails (A) and a gear mechanism (B). The axial track is locked in place with 2 – 12mm hex bolts that are 230mm long (C).
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Failure to follow the instructions to shift the Patriot II when it is equipped with the axial shift option may cause damage to the bar feeder or lathe. All attaching components must be installed and tightened prior to production. Follow the lathe manufacturer’s instructions for converting to non-guide bushing mode. With the bar feed in manual operation, ensure there are no active faults.
5.7 Axial Shift Instructions – Non-Guide Bushing Mode to Guide Bushing Mode All attaching components must be installed and tightened prior to production. With the bar feeder in manual operation, be sure there are no active faults. Place lathe headstock in forward overtravel position Swiss mode. Place the bar feed into the Emergency Stop condition.
5.8 Tower Light The indicator light provides quick visual indication of bar feeder status. The bar feeder PLC directly controls the operation of the tower light. Status conditions include: • Red light is on, the bar feeder is in alarm. •...
5.9 Spindle Liner Prior to spindle liner insertion or removal, ensure the lathe is in Emergency Stop or that power to the lathe is off. Never remove or install a spindle liner to a spindle that can be powered on during this process. Do not operate the lathe if the extended cover is off while using an extended spindle liner.
Contact Edge Technologies for more information. Telescopic nose: For lathes with a sliding headstock, the telescopic nose bridges the gap between the front of the bar feeder and the back end of the lathe.
6. Systems and Adjustments 6.1 MAVD Adjustment of Wheels For optimal machine operation, properly adjust the close position of the rollers of the MAVD. Proper adjustment supports the bar and reduces vibrations during production. Lathe and bar feeder must be in manual mode during the adjustment of the MAVD.
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To adjust the open and close speeds of the MAVD, use the flow control bolts on the cylinder. When the lathe collet is closed, the MAVD rollers/blocks will be closed if the parameter is set to operate this way. Pressing the pre-auto button with the lathe collet closed will command the MAVD to close. Adjust the speed as desired.
6.2 Magazine Adjustment Follow the procedure below any time the bar diameter requires changing. When adjusting the magazine, be sure the lathe and bar feeder are in Emergency Stop. Adjusting the magazine can produce pinch points between magazine and material. Place the lathe and bar feeder into Emergency Stop prior to adjusting magazine.
6.3 Anti-Vibration Device with Air Knife Bushing block cover is removable and must be in place for safe operation of the bar feeder. Bushing blocks should only be changed out when there is no material in the bar feeder and when the bar feeder is in Emergency Stop. Anti-Vibration Device A.
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The Patriot’s unique anti-vibration device provides material support upon discharge from the channel. Bar feeder oil is supplied to the device to aid in vibration reduction. The telescopic / hard nose attaches to the end of the device. In Automatic mode, the bushing blocks will shadow the lathe collet open and closing. When the bushing block cover is removed, the blocks are prevented from closing as a safety feature.
6.4 Synchronization System The synchronization system will move at random times during the automatic operation. Access covers to the synchronization device should always be in place during operation. The synchronization belt adjustment should only be performed when the bar feeder electrical power has been removed. Follow local, state and federal lockout/tagout standards.
The Patriot comes standard with 3 collet screw-on tip adapters. An adapter with a pin attaching style is available from Edge Technologies as well. Refer to Parts section for part numbers and available sizes. The rotating tip diameter should be 1mm smaller in diameter than the guide channel set.
This may require cutting the upper chain channel to remove the bolts. Contact Edge Technologies for additional information. A pre-feed pusher and pusher are included in every new guide channel set. The old style uses flathead bolts, whereas the new style uses low-profile socket head bolts.
6.7 Guide Channel System Machine damage will occur if the lower channel is installed in the upper channel locations. This will keep the flow of oil from reaching the channel. The Patriot Gen II uses a new guide channel system. It’s a toolless application, so the time to install the guide channel is much faster.
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Install the guide channels from first to last represented here. (Note, longer machine will have more guide channels.) This illustration shows you how to properly install the pre-feed pusher channel. A set pin (A) keeps the pre-feed pusher from moving back and forth. This is the top guide channel set in the pre-feed pusher area.
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Guide Channel Mechanical lever The guide channels are held in place by this mechanical lever. To lock the guide channel in place, push the spring-loaded lever set bolt (A) towards home position. Rotate the lever counterclockwise (B) Once the lever is pushed counterclockwise, release the spring-loaded lever set bolt (C) The pre feed hanger uses a tooless bolt (A) Place the hanger and tighten the bolt.
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This illustration shows the bottom guide channel set post-gripper. Install the guide channels from first to last represented here. A set pin (A) keeps the guide channels from moving back and forth. (Note, longer machine will have more guide channels.) The set pin (A) keeps the guide channels from moving back and forth.
6.8 Shuttle – Extraction / Introduction Cylinder Never adjust the air valves without being properly trained. Personal injury could result. The Patriot is equipped with a robust extraction and insertion system designed to provide exceptional durability. The operation of this cylinder is known as the shuttle. During introduction of the bar feeder collet onto the bar end, the servo drive motor is engaged with the shuttle (air cylinder) moving simultaneously.
6.9 Channel Lock System The channel lock system on the Patriot maintains guide channel closure during production (A). As the bar is rotated and the channel is filled with pressurized oil, this pressure could force the channel open. A pneumatic cylinder controls the opening and closing of the lock mechanism (B).
6.10 Material Standards and Requirements The ends of the bar should be relatively straight to the bar diameter to ensure proper positioning as the bar reaches the facing position and to keep the bar pusher from sliding off the bar while feeding the material. In most cases, chamfering the front end of the bar is required.
6.11 Procedure to Check Bar Straightness 1) Find a suitable surface to allow the bar to rest on V-blocks without any rocking movement. 2) Rotate the bar 360°. Record the dial indicator readings at each location. 3) Calculate both the tolerance for each meter increment and the tolerance over the entire length of bar.
6.12 Bar Stock Preparation Bar stock must be free of burrs, chips and excessive dirt. Clean bars will extend the life of the guide channel set and bearing unit of the pusher, as well as the oil pump impeller. Bar ends should be relatively square to the length of the bar.
7. Control Operations 7.1 HMI Description Only trained personnel should operate the bar feeder. The Patriot bar feeder features a 7” full touchscreen HMI. The HMI is a microprocessor-based, touchscreen unit that receives user input commands directly through the touchscreen. Understanding the function of the HMI is essential in operating the bar feeder.
7.4 Power Up Improper use of the electrical cabinet can result in electric shock that will kill the operator and damage the machine. Have the bar stock in the bar feeder magazine and the lathe ready for production to power up and place the bar feeder in Automatic mode.
7.8 Loading with the Bar On and Bar Off Buttons Do not use Bar On if a bar is already in the bar feeder. Doing so will cause damage to the machine. Bar On A new bar can be loaded by using the Bar On button. The lathe collet must be open for Bar On to function.
8. Parameters 8.1 Parameter Pages and Definitions: Part Menus Feedout 1: When only using one feedout, this is the part length. If you wish to use multiple feedouts, modify the values in the additional feed lengths screen. Calculate the proper setting by adding the length of part + width of cut-off tool + facing stock.
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Remnant Ejection: Eject With New Bar uses the next bar to eject the remnant from the lathe spindle. Eject With Pusher uses the pusher to eject the remnant from the lathe. The distance to eject is set in the factory menu. Total Feed Length: This sets the total length of the part to be machined.
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Facing Length: The additional length the bar will be fed after the facing position is reached. Min Bar Length: If a bar is measured at less than this length, the bar feeder will alarm out. Setting this properly will help with process reliability. Max Bar Length: If a bar is measured at more than this length, the bar feeder will alarm out.
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Open Collet Feeding Torque: This represents the maximum possible torque when feeding the bar into the lathe. Larger bars may need higher torque. If the torque is set too high for thin bars, it is possible to bend the bar and subsequently break a tool during machining. Open Collet Speed: This represents the speed that the bar will be fed into the lathe.
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Open Collet Timeout: When the bar feeder is in automatic, if the lathe collet is open for longer than the open collet timeout, the bar feeder will alarm out. [57]...
8.2 Parameter Pages and Definitions: Factory Menus MCode Yes/No: MCode Feed commands the bar feeder to feed the bar. If MCode is set to yes, when the collet opens, the bar feeder will require the MCode feed signal (sent from the lathe) to feed a part.
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End of Bar Type: Pulse enables the pulse timer for the end of bar. Latch, which is used for most lathes, turns the end-of-bar signal on until the bar change is complete. Double Pulse does 2 pulses instead of one to improve signal reliability on lathes where a single pulse is unreliable (extending the pulse timer can also help).
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Max End of Bar Position: This is the maximum position of the pusher when feeding the bar into the lathe. It is used to ensure that the chuck jaws are gripping enough material to machine a new part. Facing Distance: This is the distance from the measurement flag to the face of the lathe collet or chuck.
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Oil Pump Shutoff Position: This is the position to shut off the oil pump. This position should be after the pusher collet has moved past the guide channels. Setting this position too far could result in undesired oil transfer to the lathe. Front of Prefeed to Measure Flag Distance: This is the distance between the front of the prefeed pusher at the prefeed position and the measurement flag.
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Pushback Collet Open: When the collet is open, if the pusher is forced back more than this amount, the bar feeder will alarm out. A value of zero will ignore this alarm. It is mostly used for Swiss-type applications. Pushback Collet Closed: When the collet is closed, if the pusher is pushed back further than this amount, the bar feeder will alarm out.
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Manual Speed: While in manual mode, this is the speed the pusher will move when the left/right arrow buttons on the handheld pendant are pushed. Bar Change Return Speed: After the lathe sends the bar change command, the pusher will travel to the Home reference position at this speed.
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Facing Speed: This is the pusher speed before the bar reaches a point it can be measured (controlled by maximum bar length) and after a bar has been measured. Homing Speed: This is the speed the pusher travels when trying to find the Home reference position. Slower speed prevents the pusher from slamming into the back of the machine.
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Manual Pusher Torque: This is the max torque the pusher will exert when doing manual moves. Insertion / Extraction Torque: This is the torque used to assist the cylinder during insertion and extraction. Pullout From Lathe Torque: When pulling the remnant out of the lathe, the bar feeder will use this torque until the pusher has pulled back the distance entered in the pullout from the lathe distance parameter (see Factory menu).
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Anti-Vibration Opening Position: At this position, the first AVD will open. This position should be before the pusher collet reaches the first anti-vibration device. Anti-Vibration Reclose Position: At this position, the AVD will reclose on the pusher. This stabilizes the pusher and helps reduce vibration. This position should be after the pusher collet passes fully through the AVD.
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Cycle Start Pulse Timer: This sets the amount of time to keep on the cycle start signal. 0 is latch. The bar feeder will wait for the collet to close before turning the signal off. Feed Confirm Pulse Timer: This sets the amount of time to keep on the feed confirm signal. 0 is latch. The bar feeder will wait for the collet to close before turning the signal off.
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Max Pecking Cycles: When feeding the bar into the spindle, if the bar feeder detects the bar is stuck, it will "peck" the bar the number of times in this parameter by repeatedly backing up and pushing again. If the bar is still stuck after pecking this many times, the bar feeder will alarm out. [68]...
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Loading an Existing Part Select a part from the Part menu (1) Press “Load Program to Mem”, this copies the part from the usb drive into the PLC memory. (2) The “currently loaded part” (3) will update to show that the part that was just loaded (4) [69]...
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Creating a new part from default Press “load default” (this will load parameters in Enter the name you want the part to be called (2) for the default part that was created after the machine was installed, the default part can be changed from Admin ->...
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Modifying an existing part and saving/loading it under a new name Select a part from the Part menu (1) Press “Load Program to Mem”, this copies the (if the part is already loaded skip to step 4) part from the usb drive into the PLC memory. (2) The “currently loaded part”...
9. Maintenance 9.1 General Maintenance Tips Prior to bar feeder maintenance, turn off 3-phase power to the bar feeder and place the lathe into an Emergency Stop. Prior to pneumatic system service, evacuate the system. Using petroleum or other solvents on the bar feeder may damage plastic components.
9.2 Pusher Drive Chain Bar feeder and lathe must be in Emergency Stop for belt adjustment. Properly trained personnel are required to adjust the drive chain. Do not set chain tension too tight. This will stretch the chain and potentially lead to failure.
9.3 Inspecting the Pusher Collet and Revolving Tip The pusher collet and revolving tip are right next to the gripper. Make certain that the power supply is disconnected before attempting to inspect! Check that the revolving tip (A) rotates smoothly and does not have excessive runout. If any problems are detected, replace the tip.
9.4 Inspecting the Air Regulator Always use proper eye protection when working with compressed air systems. • Check the bottle (A) for water. • Press button (B) to exhaust water out of bottle. Inspect for the following and repair any issues that are found: •...
9.5 Replacing Gripper Blades The gripper is a pinch hazard. Its assembly is a moving component that should always be serviced with electrical power and air supply removed. Place the lathe and bar feeder into Emergency Stop when replacing gripper jaws. The gripper device is used to press material onto the bar feeder collet and remove remnants from the collet.
9.6 How to Tension the Synchronization Belt Place bar feeder in Emergency Stop. Remove front cover from the bar feeder. Loosen lock nut (1). Loosen the adjustment plate locking bolts (2). Rotate the adjustment bolt (3) clockwise to tighten belt tension / counterclockwise to loosen belt.
10. Alarms 10.1 Alarm Table Only a qualified electrician or serviceman should perform electrical troubleshooting or maintenance to this equipment. [79]...
11. Interface Signal Definitions Common (from lathe) – This is the 24v DC supply voltage from the lathe for signal sent to the bar feeder control. The voltage cannot be mixed with the bar feeder power supply. Cycle start (bar change end, program start) – Typically, this is a normally open circuit controlled by the bar feeder Cycle Start/MCode Finish relay.
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This could be because of a wiring issue. It could also be that the bar feeder interface is not turned on in the lathe. Lathe manual/auto – Edge Technologies products typically use this to limit feeding. If the bar feeder does not see the lathe automatic signal, it will not feed material when the collet opens.
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Bar feeder Emergency Stop - Signal will be sent to the lathe to generate Emergency Stop on the lathe. Power supply – Always check voltage at the lathe plug before the bar feeder is plugged in. The bar feeder plug wiring should also be checked to the wiring print supplied with the bar feeder. Check the wiring of the bar feeder plug, check that the lathe voltage is on the same pins as the plug, and check that the voltage of the lathe is proper and does not fluctuate beyond safe operating voltage.
Direct service questions to (314) 810-3927 or edgehelp@edgetechnologies.com. Edge Technologies’ hours of operation are Monday-Thursday, 7:30 a.m. to 5 p.m. CST, and Friday, 7:30 a.m. to 4 p.m. CST. Contact the main phone at (314) 692-8388. For helpful tutorials, visit our Youtube page at https://www.youtube.com/@EdgeTechnologies.
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(12FT - Bar length - 3800MM - 12’5”) (12FT - XL- Ma 7 MM 274 MM (12FT - Bar length - 3800MM - 12’5”) (12FT - St 6.8”) (10.8”) Technical data subject to change without notice EDGE TECHNOLOGIES PUSHING AUTOMATION FORWARD 11600 Adie Road Saint Louis, MO 63043 314.692.8388 www.edgetechnologies.com...
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